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Author: Ameli, Amir × End date: 2019 × Start date: 2011 ×

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    Extruded polycarbonate/Di-Allyl phthalate composites with ternary conductive filler system for bipolar plates of polymer electrolyte membrane fuel cells
    (Bristol : IOP Publ., 2019) Naji, Ahmed; Krause, Beate; Pötschke, Petra; Ameli, Amir
    Here, we report multifunctional polycarbonate (PC)-based conductive polymer composites (CPCs) with outstanding performance manufactured by a simple extrusion process and intended for use in bipolar plate (BPP) applications in polymer electrolyte membrane (PEM) fuel cells. CPCs were developed using a ternary conductive filler system containing carbon nanotube (CNT), carbon fiber (CF), and graphite (G) and by introducing di-allyl phthalate (DAP) as a plasticizer to PC matrix. The samples were fabricated using twin-screw extrusion followed by compression molding and the microstructure, electrical conductivity, thermal conductivity, and mechanical properties were investigated. The results showed a good dispersion of the fillers with some degree of interconnection between dissimilar fillers. The addition of DAP enhanced the electrical conductivity and tensile strength of the CPCs. Due to its plasticizing effect, DAP reduced the processing temperature by 75 °C and facilitated the extrusion of CPCs with filler loads as high as 63 wt% (3 wt% CNT, 30 wt% CF, 30 wt% G). Consequently, CPCs with the through-plane electrical, in-plane electrical and thermal conductivities and tensile strength of 4.2 S cm-1, 34.3 S cm-1, 2.9 W m-1 K-1, and 75.4 MPa, respectively, were achieved. This combination of properties indicates the potential of PC-based composites enriched with hybrid fillers and plasticizers as an alternative material for BPP application.
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    Hybrid conductive filler/polycarbonate composites with enhanced electrical and thermal conductivities for bipolar plate applications
    (Manchester, NH : Wiley, 2019) Naji, Ahmed; Krause, Beate; Pötschke, Petra; Ameli, Amir
    Conductive polymer composites (CPCs) with high electrical and thermal conductivities are demanded for bipolar plates of fuel cells. In this work, CPCs of polycarbonate (PC) filled with carbon nanotube (CNT), carbon fiber (CF), graphite (G), and their double and triple hybrids were prepared using solution casting method followed by compression molding. The results showed that the electrical percolation thresholds for the PC-CNT and PC-CF were ~1 wt% and ~10 wt%, respectively, while no clear threshold was found for PC-G composites. Addition of 3–5 wt% CNT improved the electrical conductivity of PC-CF and PC-G systems up to 6 orders of magnitude and enhanced the thermal conductivity as much as 65%. The results of triple hybrid CPCs (with constant loading of 63 wt%) indicated that the combination of highest electrical and thermal conductivities is achieved when the CF and CNT loadings were near their percolation thresholds. Therefore, a triple filler system of 3 wt% CNT, 10 wt% CF, and 50 wt% G resulted in a composite with the through-plane and in-plane electrical conductivity, and thermal conductivity values of 12.8 S/cm, 8.3 S/cm, and 1.7 W/m•K, respectively. The results offer a combination of properties surpassing the existing values and suitable for high-conductivity applications such as bipolar plates. POLYM. COMPOS., 40:3189–3198, 2019. © 2018 Society of Plastics Engineers.
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    Bidirectional and Stretchable Piezoresistive Sensors Enabled by Multimaterial 3D Printing of Carbon Nanotube/Thermoplastic Polyurethane Nanocomposites
    (Basel : MDPI, 2018-12-21) Christ, Josef F.; Aliheidari, Nahal; Pötschke, Petra; Ameli, Amir
    Fabricating complex sensor platforms is still a challenge because conventional sensors are discrete, directional, and often not integrated within the system at the material level. Here, we report a facile method to fabricate bidirectional strain sensors through the integration of multiwalled carbon nanotubes (MWCNT) and multimaterial additive manufacturing. Thermoplastic polyurethane (TPU)/MWCNT filaments were first made using a two-step extrusion process. TPU as the platform and TPU/MWCNT as the conducting traces were then 3D printed in tandem using multimaterial fused filament fabrication to generate uniaxial and biaxial sensors with several conductive pattern designs. The sensors were subjected to a series of cyclic strain loads. The results revealed excellent piezoresistive responses with cyclic repeatability in both the axial and transverse directions and in response to strains as high as 50%. It was shown that the directional sensitivity could be tailored by the type of pattern design. A wearable glove, with built-in sensors, capable of measuring finger flexure was also successfully demonstrated where the sensors are an integral part of the system. These sensors have potential applications in wearable electronics, soft robotics, and prosthetics, where complex design, multi-directionality, embedding, and customizability are demanded.